Copyright 1999 Society of Manufacturing Engineers FUNDAMENTAL MANUFACTURING PROCESSES Welding NARRATION (VO):

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1 Copyright 1999 Society of Manufacturing Engineers FUNDAMENTAL MANUFACTURING PROCESSES Welding SCENE 1. CG: Fusion Welding Processes white text centered on black SCENE 2. tape 528, 14:18:33-14:18:52 flux-core arc welding using filler metal IN FUSION WELDING, METAL COALESCENCE IS CREATED BY MELTING A BASE METAL AND FILLER METAL TOGETHER, OR BY MELTING THE BASE METAL ALONE. SCENE 3. tape 520, 07:01:00-07:02:00 blue background CG: Fusion Welding Processes Arc Welding Resistance Welding Laser Beam Welding Electron Beam Welding THE PRINCIPAL FUSION WELDING PROCESSES ARE: ARC WELDING, RESISTANCE WELDING, LASER BEAM WELDING, AND ELECTRON BEAM WELDING. SCENE 4. tape 525, 12:07:32-12:07:52 arc welding CG, SUPER: Arc Welding ARC WELDING PROCESSES USE AN ELECTRIC ARC AS THE HEAT SOURCE TO MELT AND JOIN THE BASE METALS. THE ARC IS STRUCK BETWEEN THE WORKPIECES AND THE TIP OF AN ELECTRODE. SCENE 5. tape 519, 05:13:38-05:13:47 consumable arc welding tape 525, 12:11:59-12:12:06 non-consumable arc welding ARC WELDING ELECTRODES ARE USUALLY CONSUMABLE..., BUT CAN BE NON-CONSUMABLE. SCENE 6. tape 517, 02:13:45-02:14:15

2 Copyright 1999 Society of Manufacturing Engineers pan from consumable electrode wire rolling off to arc welding tape 530, 16:03:35-16:03:44 slag covering being removed THE CONSUMABLE ELECTRODE IS USUALLY WIRE OR ROD, AND THE CURRENT THAT SUSTAINS THE ARC ALSO MELTS THE ELECTRODE SO THAT IT SUPPLIES FILLER METAL TO THE JOINT. THE ELECTRODE MAY ALSO PRODUCE A SLAG COVERING TO PROTECT THE HOT WELD METAL FROM OXIDATION. SCENE 7. tape 525, 12:14:28-12:14:34 tungsten rod being placed in welding gun tape 525, 12:12:42-12:12:55 gas tungsten arc welding, with filler metal supplied to joint THE MOST COMMON NONCONSUMABLE ELECTRODE IS A TUNGSTEN ROD, WHICH CARRIES THE ELECTRIC CURRENT. IF A WELDING OPERATION USING A NONCONSUMABLE ELECTRODE ALSO REQUIRES A FILLER METAL, IT IS SUPPLIED BY A SEPARATE WIRE, ROD OR CONSUMABLE INSERT. SCENE 8. tape 517, 02:03:55-02:04:04 electrode moved manually tape 529, 15:02:53-15:03:12 electrode moved mechanically WHILE WELDING, THE ELECTRODE IS MOVED EITHER MANUALLY..., OR MECHANICALLY ALONG THE JOINT, OR THE ELECTRODE IS HELD STATIONARY AND THE WORKPIECE IS MOVED. SCENE 9. tape 528, 14:26:15-14:26:25 arc welding process tape 520, 07:01:00-07:02:00 blue background CG: Arc Welding Processes Shielded Metal Arc Welding (SMAW) Submerged Arc Welding (SAW) Gas Metal Arc Welding (GMAW, MIG) Flux-Cored Arc Welding (FCAW) Gas Tungsten Arc Welding (GTAW, TIG, Heliarc) Plasma Arc Welding (PAW, Needle Arc) ARC WELDING ENCOMPASSES A VARIETY OF PROCESSES, THE PRIMARY TYPES BEING: SHIELDED METAL ARC WELDING, SUBMERGED ARC WELDING, GAS METAL ARC WELDING, FLUX-CORED ARC WELDING, GAS TUNGSTEN ARC WELDING, AND PLASMA ARC WELDING.

3 Copyright 1999 Society of Manufacturing Engineers SCENE 10. CG, SUPER: Shielded Metal Arc Welding tape 529, 15:23:45-15:23:53 shielded metal arc welding tape 533, 18:00:40-18:01:10 GRAPHIC: stick tape 533, 18:01:40-18:02:10 GRAPHIC: stick with enlarged cross section tape 529, 15:23:57-15:24:18 shielded metal arc welding CG, SUPER: Source Of Arc Stabilizers Fluxing Agents Lubricants Gases To Displace Air Metal & Slag To Protect, Support & Insulate The Hot Weld Metal During Welding SHIELDED METAL ARC WELDING USES A COVERED ELECTRODE CONSISTING OF A CORE WIRE SURROUNDED BY A CONCENTRIC COVERING WHICH IS A MIXTURE OF SILICATE BINDERS AND POWDERS. THESE BINDERS AND POWDERS SERVE AS A SOURCE OF ARC STABILIZERS, FLUXING AGENTS, LUBRICANTS, GASES TO DISPLACE AIR, AND METAL AND SLAG TO PROTECT, SUPPORT AND INSULATE THE HOT WELD METAL DURING WELDING. SCENE 11. tape 530, 16:12:38-16:12:47 bare section of electrode clamped in holder tape 530, 16:16:02-16:16:12 workpiece connected to power source THE BARE SECTION OF THE ELECTRODE IS CLAMPED IN A HOLDER, WHICH IS CONNECTED BY A WELDING LEAD, OR CABLE, TO A TERMINAL OF A CONSTANT CURRENT POWER SOURCE. THE WORKPIECE IS CONNECTED TO THE OTHER POWER-SOURCE TERMINAL. SCENE 12. tape 530, 16:05:38-16:06:09 touching the tip of the electrode against the workpiece, initiating arc, arcing electrode moves out of shot, showing weld TOUCHING THE TIP OF THE ELECTRODE AGAINST THE WORKPIECE AND WITHDRAWING IT SLIGHTLY INITIATES, OR STRIKES, THE ARC. THE HEAT OF THE ARC MELTS THE BASE METAL IN THE IMMEDIATE AREA AS WELL AS THE ELECTRODE CORE WIRE AND COVERING. THE MOLTEN BASE METAL, CORE WIRE AND METAL POWDERS IN THE COVERING

4 Copyright 1999 Society of Manufacturing Engineers COALESCE, OR FUSE, TO FORM THE WELD. SCENE 13. tape 530, 16:15:24-16:16:00 wide, arc welding process CG, SUPER: Alternating-Current Or Ac /Direct- Current Or Dc Power Source Welding Leads Electrode Holder Welding Helmet & Gloves Protective Clothing THE EQUIPMENT REQUIRED FOR SHIELDED METAL ARC WELDING INCLUDES EITHER AN ALTERNATING-CURRENT OR AC OR DIRECT-CURRENT OR DC POWER SOURCE, WELDING LEADS, AN ELECTRODE HOLDER, WELDING HELMET AND GLOVES, AND PROTECTIVE CLOTHING. SCENE 14. tape 530, 16:19:00-16:19:17 shielded metal arc welding CG, SUPER: Ferrous Metals Cast Iron Carbon Steels Low-Alloy Steels Stainless Steels Tool Steels Non-Ferrous Metals Copper Nickel Aluminum THE PROCESS IS EFFECTIVE FOR WELDING FERROUS METALS SUCH AS CAST IRON, CARBON, LOW-ALLOY, STAINLESS AND TOOL STEELS; AND NON-FERROUS METALS INCLUDING COPPER, NICKEL, ALUMINUM AND THEIR ALLOYS. SCENE 15. CG, SUPER: Submerged Arc Welding tape 528, 14:08:14-14:08:34 submerged arc welding tape 528, 14:10:48-14:10:20 spark struck, starting submerged arc welding, hand held, zoom out IN SUBMERGED ARC WELDING, A BARE, CONTINUOUS, CONSUMABLE ELECTRODE WIRE, SHIELDED BY A LAYER OF GRANULAR FLUX PARTICLES, SUSTAINS THE ARC. WHEN THE ARC IS STRUCK, THE TIP OF THE ELECTRODE IS SUBMERGED IN THE FLUX AND THE ARC IS NOT VISIBLE. WELDING PROCEEDS WITHOUT THE INTENSE RADIATION THAT CHARACTERIZES OPEN-ARC PROCESSES, AND WITH LITTLE FUMES. SCENE 16. tape 529, 15:03:38-15:03:48 wide, submerged arc welding THE SUBMERGED ARC WELDING PROCESS VARIES FROM

5 Copyright 1999 Society of Manufacturing Engineers SEMIAUTOMATIC, TO FULLY AUTOMATIC. SCENE 17. tape 529, 15:02:43-15:02:56 pan from wire feeding device to joint-tracking systems moving the welding head EQUIPMENT INCLUDES AUTOMATIC WIRE-FEED DEVICES..., AND JOINT-TRACKING SYSTEMS TO MOVE EITHER THE WELDING HEAD, OR THE WORKPIECE. SCENE 18. tape 528, 14:09:22-14:09:37 submerged arc welding CG, SUPER: All Types Of Steel Stainless Steels Nickel Alloys SUBMERGED ARC WELDING IS COMMONLY USED TO JOIN ALL TYPES OF STEEL, STAINLESS STEELS, AND NICKEL ALLOYS. SCENE 19. CG, SUPER: Gas Metal Arc Welding tape 525, 12:05:51-12:06:12 zoom in, robotic gas metal arc welding GAS METAL ARC WELDING USES A CONTINUOUS, SOLID, WIRE ELECTRODE FOR THE FILLER METAL AND A SHIELDING GAS TO PROVIDE THE DESIRED ARC CHARACTERISTICS AND PROTECT THE MOLTEN WELD METAL FROM AIR. SCENE 20. tape 519, 05:10:22-05:10:34 gas metal arc welding GAS METAL ARC WELDING IS SUITABLE FOR WELDING MANY TYPES OF JOINTS OF MOST ANY METAL IN ALL WELDING POSITIONS. SCENE 21. tape 517, 02:09:36-02:09:53 gas metal arc welding tape 517, 02:25:56-02:26:22 gas metal arc welding CG, SUPER: Short-Circuiting Transfer Globular Transfer Spray Transfer THE CHARACTERISTICS OF THE GAS METAL ARC WELDING PROCESS ARE BEST DESCRIBED IN TERMS OF THE THREE BASIC MODES BY WHICH METAL IS TRANSFERRED FROM THE ELECTRODE TO THE WORK: THE SHORT CIRCUITING TRANSFER,

6 Copyright 1999 Society of Manufacturing Engineers THE GLOBULAR TRANSFER, AND THE SPRAY TRANSFER. SCENE 22. & previous CG, SUPER tape 517, 02:10:52-02:11:13 c.u. gas metal arc welding CG, SUPER: The Magnitude & Type Of Welding Current Electrode Diameter Composition Of The Electrode Electrode Extension/Length The Type Of Shielding Gas SCENE 23. CG, SUPER: Short Circuiting Transfer High Speed Video Micrography GRAPHIC: add mask to accentuate the actual deposition of weld metal tape 535, 19:27:52-19:28:25 c.u. slow motion, shortcircuiting gas metal arc welding tape 535, 19:21:40-19:22:12 c.u. slow motion, shortcircuiting gas metal arc welding THE TYPE OF TRANSFER IS DETERMINED BY A NUMBER OF FACTORS, THE MOST SIGNIFICANT INCLUDING: THE MAGNITUDE AND TYPE OF WELDING CURRENT, THE ELECTRODE DIAMETER, THE COMPOSITION OF THE ELECTRODE, THE ELECTRODE EXTENSION OR LENGTH, AND THE TYPE OF SHIELDING GAS. THE SHORT CIRCUITING TRANSFER MODE ENCOMPASSES THE LOWEST RANGE OF WELDING CURRENTS AND ELECTRODE DIAMETERS ASSOCIATED WITH GAS METAL ARC WELDING. METAL IS TRANSFERRED FROM THE ELECTRODE TO THE WORK ONLY DURING INTERVALS OF CONTROLLED SHORT CIRCUITS. THE SHORT CIRCUITING TRANSFER MODE IS GENERALLY SUITED FOR JOINING THIN SECTIONS, BRIDGING LARGE ROOT OPENINGS, AND FOR WELDING IN ALL POSITIONS. SCENE 24. CG, SUPER: Globular Transfer High Speed Video Micrography GRAPHIC: add mask to accentuate the actual deposition of weld metal tape 535, 19:22:48-19:23:15 c.u. slow motion, globulartransfer gas metal arc welding THE GLOBULAR-TRANSFER MODE IS CHARACTERIZED BY DROP SIZES WITH A DIAMETER LARGER THAN THAT OF THE ELECTRODE. THESE MOLTEN DROPS ARE EASILY ACTED ON BY GRAVITY, USUALLY LIMITING SUCCESSFUL TRANSFER TO THE FLAT POSITION. SCENE 25. CG, SUPER: Spray Transfer High Speed Video

7 Copyright 1999 Society of Manufacturing Engineers Micrography GRAPHIC: add mask to accentuate the actual deposition of weld metal tape 535, 19:13:24-19:14:00 c.u. slow motion, spray transfer gas metal arc welding THE SPRAY TRANSFER MODE DEPOSITS SMALL DROPLETS OF METAL AT RATES OF SEVERAL HUNDRED PER SECOND. SPRAY TRANSFER REQUIRES HIGH ELECTRIC CURRENT, AND ARGON OR ARGON-RICH GAS MIXTURES TO SHIELD THE ARC. METAL TRANSFER IS STABLE, DIRECTIONAL AND VIRTUALLY SPATTER-FREE. SCENE 26. CG, SUPER: Flux-Cored Arc Welding tape 528, 14:17:54-14:18:08 flux-cored arc welding, pan up to wire spooling CG, SUPER: Carbon Steels Low Alloy Steels Stainless Steels Cast Iron FLUX-CORED ARC WELDING USES A FILLER METAL MADE UP OF A TUBULAR ELECTRODE WITH A FLUX CORE AND WITH OR WITHOUT ADDITIONAL GAS SHIELDING TO JOIN CARBON STEELS, LOW ALLOY STEELS, STAINLESS STEELS, AND CAST IRON. SCENE 27. tape 520, 08:01:40-08:02:20 GRAPHIC: flux core wire CG, SUPER: Minerals Ferroalloys Ingredients That Provide Shielding Gases, Deoxidizers, & Slag-Forming Materials tape 528, 14:22:48-14:23:00 flux core welding CG, SUPER: Arc Stability Enhance Weld-Metal Properties Improve Weld Bead Contour THE CORE MAY CONTAIN MINERALS, FERROALLOYS AND INGREDIENTS THAT PROVIDE SHIELDING GASES, DEOXIDIZERS, AND SLAG-FORMING MATERIALS. THESE INGREDIENTS PROMOTE ARC STABILITY, ENHANCE WELD- METAL PROPERTIES AND IMPROVE WELD BEAD CONTOUR. SCENE 28. CG, SUPER: Gas Tungsten Arc Welding tape 529, 15:17:21-15:17:50 zoom out, gas tungsten arc welding GAS TUNGSTEN ARC WELDING USES A NONCONSUMABLE TUNGSTEN ELECTRODE AND EXTERNALLY SUPPLIED INERT- GAS SHIELDING. SCENE 29.

8 Copyright 1999 Society of Manufacturing Engineers CG, SUPER: Argon Helium Mixtures Of The Two THE MOST COMMON SHIELDING GASES USED ARE ARGON AND HELIUM AND MIXTURES OF THE TWO GASES. SCENE 30. ALL TYPES OF STEELS AND MOST NONFERROUS METALS CAN BE WELDED IN ALL KINDS OF JOINTS AND POSITIONS. SCENE 31. tape 529, 15:20:34-15:20:44 zoom out, gas tungsten arc welding tape 525, 12:17:48-12:17:55 gas tungsten arc welding, with filler metal supplied to joint DEPENDING ON THE APPLICATION, WORKPIECES CAN BE WELDED WITHOUT A FILLER METAL..., OR WELDED WITH A FILLER METAL SUPPLIED SEPARATELY TO THE JOINT. SCENE 32. tape 525, 12:16:12-12:16:29 zoom out, power source to gas tungsten arc welding THE GAS TUNGSTEN ARC WELDING PROCESS EMPLOYS EITHER AN ALTERNATING-CURRENT OR DIRECT-CURRENT POWER SOURCE, DEPENDING ON THE TYPE OF METAL TO BE JOINED AND IT S THICKNESS. SCENE 33. tape 529, 15:16:39-15:17:08 gas tungsten arc welding SOME POWER SOURCES PROVIDE PULSATING DIRECT CURRENT WITH VARIABLE FREQUENCY. THESE ADJUSTMENTS ALLOW BETTER CONTROL OF THE MOLTEN WELD METAL WHEN WELDING THIN SECTIONS AND WHEN WELDING IN OTHER THAN THE FLAT POSITION. SCENE 34. CG, SUPER: Plasma Arc Welding tape 526, 13:19:11-13:19:26 zoom out, plasma arc welding tape 536, 00:08:30-00:09:30 ANI: cut away of plasma arc welding head, gas surrounding the tungsten electrode within IN PLASMA ARC WELDING, METAL COALESCENCE IS PRODUCED BY A CONSTRICTED ARC MADE UP OF A HIGH- VELOCITY STREAM OF IONIZED GAS, CALLED A PLASMA.

9 Copyright 1999 Society of Manufacturing Engineers the orifice body, forming the plasma jet, with auxiliary shielding gas CG, SUPER: add arrow showing gas flowing down inside torch chamber CG, SUPER: add arrow showing gas flowing through constricted orifice IN MOST PLASMA ARC WELDING OPERATIONS THE PLASMA JET IS GENERATED BY HEATING THE ORIFICE GAS IN THE TORCH PLENUM CHAMBER TO A PLASMA AND FORCING THE PLASMA TO EXIT THROUGH A CONSTRICTING NOZZLE OR ORIFICE. SCENE 35. continue previous animation CG, SUPER: add arrows showing auxiliary gas CG, SUPER: Argon Helium Argon/Hydrogen Argon/Helium PARTIAL SHIELDING IS OBTAINED FROM THE PLASMA AND IS SUPPLEMENTED BY AN AUXILIARY SHIELDING GAS. AUXILIARY SHIELDING GASES USED INCLUDE ARGON, HELIUM OR MIXTURES OF ARGON WITH HYDROGEN OR HELIUM. SCENE 36. tape 526, 13:20:40-13:20:54 plasma arc welding tape 520, 07:01:00-07:02:00 blue background CG: Permits Deep Penetration Narrow Welds Rapid Welding Speeds Good Arc Stability tape 526, 13:06:15-13:06:28 plasma arc welding BECAUSE OF THE CONSTRICTED ARC, THE HEAT ENERGY OF THE PLASMA STREAM IS CONCENTRATED AND EXTREMELY INTENSE. THIS PERMITS DEEP PENETRATION, NARROW WELDS AND RAPID WELDING SPEEDS WITH GOOD ARC STABILITY. WORKPIECES CAN BE JOINED WITH OR WITHOUT FILLER METAL. SCENE 37. tape 526, 13:04:44-13:05:05 wide, plasma arc welding PLASMA ARC WELDING CAN BE USED TO JOIN MOST FERROUS AND NONFERROUS METALS, INCLUDING EXTREMELY THIN MATERIALS, SUCH AS FOILS. SCENE 38. PLASMA ARC WELDING EQUIPMENT COST IS HIGH, HOWEVER, SO THE PROCESS IS OFTEN LIMITED IN ITS APPLICATION.

10 Copyright 1999 Society of Manufacturing Engineers SCENE 39. CG, SUPER: Resistance Welding tape 524, 11:20:02-11:20:21 resistance welding of sheet metal stock RESISTANCE WELDING PROCESSES PRODUCE COALESCENCE OF OVERLAPPING WORKPIECES WITH HEAT GENERATED BY THE RESISTANCE OF THE WORKPIECES TO THE FLOW OF ELECTRIC WELDING CURRENT, AND THE APPLICATION OF PRESSURE. SCENE 40. tape 533, 17:03:50-17:04:09 zoom out, resistance welding RESISTANCE WELDING IS PRIMARILY USED TO JOIN SHEET METAL STOCK, BUT IS SOMETIMES USED TO JOIN THIN PLATE. ALL METALS WHICH CAN BE FUSION WELDED ARE WELDABLE BY RESISTANCE WELDING. SCENE 41. tape 524, 11:26:47-11:27:35 zoom out, copper electrodes as workpiece is secured, and then welded CG, SUPER: Electrodes Conduct Welding Current To The Work/Fix The Current Density In The Weld Zone Electrodes Transmit A Force To The Workpieces Electrodes Dissipate Some Heat From The Weld Zone Electrodes Maintain Relative Alignment & position Of The Workpieces RESISTANCE WELDING PROCESSES USE COPPER ELECTRODES. THESE ELECTRODES PERFORM FOUR FUNCTIONS: THEY CONDUCT THE WELDING CURRENT TO THE WORK, AND IN SOME CASES, FIX THE CURRENT DENSITY IN THE WELD ZONE, THEY TRANSMIT A FORCE TO THE WORKPIECES, THEY DISSIPATE SOME HEAT FROM THE WELD ZONE, AND THEY MAINTAIN RELATIVE ALIGNMENT AND POSITION OF THE WORKPIECES IN SOME RESISTANCE WELDING OPERATIONS. SCENE 42. tape 533, 17:01:03-17:01:18 c.u. seam welding VERY HIGH ELECTRIC CURRENTS ARE USED TO QUICKLY PRODUCE THE RESISTANCE HEAT NECESSARY FOR FUSION. SCENE 43.

11 Copyright 1999 Society of Manufacturing Engineers tape 520, 07:01:00-07:02:00 blue background CG: Resistance Welding Spot Welding Projection Welding Seam Welding THE THREE PRINCIPAL TYPES OF RESISTANCE WELDING ARE: SPOT WELDING, SEAM WELDING, AND PROJECTION WELDING. SCENE 44. CG, SUPER: Spot Welding tape 524, 11:17:59-11:18:15 c.u. spot welding, multiple welds performed tape 532, 01:03:58-01:04:13 robotic spot welding of automotive component SPOT WELDING REFERS TO MAKING WELDS ONE AT A TIME BETWEEN THE ELECTRODES. ONE, SEVERAL OR MANY INDIVIDUAL SPOT WELDS MAY BE REQUIRED, DEPENDING ON THE APPLICATION. SPOT WELDING, WITH THE ELECTRODES MANEUVERED BY ARTICULATED-ARM ROBOTS, IS COMMONLY USED TO JOIN SHEET COMPONENTS OF AUTOMOBILES. SCENE 45. CG, SUPER: Seam Welding tape 533, 17:05:41-17:05:59 seam welding, forming leak proof weld IN SEAM WELDING, COORDINATED PULSES OF ELECTRIC CURRENT FROM ROTATING WHEEL ELECTRODES PRODUCE A SERIES OF OVERLAPPING SPOT WELDS, RESULTING IN A LEAK-TIGHT WELDED JOINT. SCENE 46. CG, SUPER: Projection Welding tape 524, 11:06:38-11:06:48 c.u. projection welding tape 518, 03:25:09-03:25:14 projections on workpiece, multiple welds performed IN PROJECTION WELDING, THE WELDS ARE LOCALIZED AT PREDETERMINED POINTS BY PROJECTIONS, EMBOSSMENTS, OR INTERSECTIONS. SEVERAL POINTS MAY BE WELDED SIMULTANEOUSLY. SCENE 47. tape 524, 11:25:03-11:25:10 wide, semiautomatic resistance welding tape 532, 01:00:34-01:00:39 wide, automated resistance welding ALL RESISTANCE WELDING METHODS USE EITHER SEMIAUTOMATIC..., OR AUTOMATIC SYSTEMS.

12 Copyright 1999 Society of Manufacturing Engineers SCENE 48. tape 524, 11:19:13-11:19:23 semiautomatic resistance welding, operator positioning workpiece tape 519, 05:07:03-05:07:09 wide, semiautomatic resistance welding, operator positioning portable welding gun, starting welding sequence tape 519, 05:02:06-05:02:12 c.u. same semiautomatic resistance welding, operator positioning portable welding gun, starting welding sequence WITH SEMIAUTOMATIC MACHINES, THE OPERATOR EITHER POSITIONS THE WORKPIECES BETWEEN THE ELECTRODES..., OR POSITIONS A PORTABLE WELDING GUN AROUND THEM AND PUSHES A SWITCH TO INITIATE THE WELD. WELDING THEN PROCEEDS ACCORDING TO A PREPROGRAMMED SEQUENCE. SCENE 49. tape 533, 17:07:38-17:07:59 zoom in, automated resistance welding AUTOMATIC MACHINES FEED WORKPIECES INTO THE MACHINE, WHERE THEY ARE WELDED AND THEN EJECTED WITHOUT OPERATOR ASSISTANCE. SCENE 50. tape 524, 11:09:57-11:10:35 wide, resistance welding system, zoom into welding CG, SUPER: Control Panel Welding Machine With A Rigid Frame Low-Voltage/High- Current Transformer Electrodes Leads Connecting Electrodes With The Welding Transformer Controls To Regulate Electric Current Pneumatic Cylinder/ Other Means Of Exerting Force To The Upper Electrode Arm THE TYPICAL RESISTANCE WELDING SYSTEM CONSISTS OF: A CONTROL PANEL, A WELDING MACHINE WITH A RIGID FRAME, A LOW-VOLTAGE, HIGH-CURRENT WELDING TRANSFORMER, ELECTRODES, LEADS CONNECTING THE ELECTRODES WITH THE WELDING TRANSFORMER, CONTROLS TO REGULATE ELECTRIC CURRENT, AND A PNEUMATIC CYLINDER OR OTHER MEANS OF EXERTING FORCE TO THE UPPER ELECTRODE ARM. SCENE 51. CG, SUPER: Laser Beam Welding tape 516, 01:04:24-01:05:10 zoom out, gas laser beam welding IN LASER BEAM WELDING, THE HEAT FOR COALESCENCE IS GENERATED BY A FOCUSED BEAM FROM A GAS OR SOLID- STATE LASER.

13 Copyright 1999 Society of Manufacturing Engineers SCENE 52. CG, SUPER: CO 2 Laser tape 521, 08:23:59-08:24:19 zoom in, solid-state laser welding CG, SUPER: YAG Laser THE MOST COMMONLY USED GAS LASER IS THE CARBON- DIOXIDE, OR CO 2 LASER, WHICH IS ACTUALLY A MIXTURE OF CARBON DIOXIDE, NITROGEN AND HELIUM GASES. THE MOST COMMONLY USED SOLID-STATE LASER IS THE NEODYMIUM-DOPED YTTRIUM-ALUMINUM GARNET, OR YAG LASER. SCENE 53. tape 522, 09:14:47-09:15:09 gas laser bean welding tape 521, 08:28:19-08:28:35 c.u. solid-state laser welding CO 2 LASERS CAN GENERATE GREATER CONTINUOUS BEAM POWER, AND ARE SUITABLE FOR WELDING THIN OR THICK WORKPIECES. YAG LASERS GENERATE LESS CONTINUOUS BEAM POWER, AND ARE GENERALLY USED TO WELD THIN WORKPIECES. SCENE 54. tape 516, 01:10:00-01:10:20 laser welding using gas shielding MOST LASER WELDS REQUIRE NO FILLER METAL, ALTHOUGH FILLER METALS CAN BE USED IF DESIRED. INERT SHIELDING GASES ARE NORMALLY EMPLOYED, USUALLY ARGON, HELIUM OR A MIXTURE OF THE TWO. SCENE 55. tape 522, 09:01:19-09:01:56 zoom in, rapid laser welding WELDING SPEEDS ARE USUALLY MUCH HIGHER THAN OTHER WELDING PROCESSES, THUS LIMITING HEAT-AFFECTED ZONE SIZE AND WORKPIECE DISTORTION. IN ADDITION, BECAUSE OF THE INTENSE, PRECISELY FOCUSED HEAT, WELDS CAN BE QUITE DEEP. ALSO, WELDS CAN BE MADE IN CONFINED REGIONS AND BETWEEN DISSIMILAR METALS. SCENE 56. tape 516, 01:11:13-01:11:23 laser beam welding tape 516, 01:21:35-01:21:57 LASER BEAM WELDING SYSTEMS ARE USED IN MANY

14 Copyright 1999 Society of Manufacturing Engineers pan, automated laser beam welding system CG, SUPER: Laser Power Supply Beam-Delivery System Workstation Motion Control System INDUSTRIES, AND ARE TYPICALLY FULLY AUTOMATED AND COMPUTER-CONTROLLED. TYPICAL EQUIPMENT INCLUDES THE LASER AND ITS POWER SUPPLY, A BEAM-DELIVERY SYSTEM WITH MIRRORS AND FOCUSING OPTICS, A WORKSTATION, AND A MOTION CONTROL SYSTEM TO MOVE EITHER THE LASER BEAM OR THE WORKPIECE. SCENE 57. tape 522, 09:06:41-09:07:19 c.u. laser welding CG, SUPER: Carbon Steels Alloy Steels Stainless Steels Aluminum Alloys Copper Alloys Magnesium Alloys Nickel Alloys Titanium Alloys Refractory Metals MANY FERROUS AND NONFERROUS METALS CAN BE JOINED USING LASER BEAM WELDING, INCLUDING CARBON, ALLOY AND STAINLESS STEELS, ALUMINUM ALLOYS, COPPER ALLOYS, MAGNESIUM ALLOYS, NICKEL ALLOYS, TITANIUM ALLOYS AND REFRACTORY METALS. SCENE 58. CG, SUPER: Electron Beam Welding tape 522, 09:23:32-09:23:48 c.u. electron beam welding IN ELECTRON BEAM WELDING, THE COALESCENCE HEAT IS GENERATED BY THE KINETIC ENERGY OF A FOCUSED STREAM OF ELECTRONS DIRECTED UPON THE JOINT. SCENE 59. tape 522, 09:22:24-09:22:50 pan down of electron beam system THE ELECTRONS ARE PRODUCED BY AN ELECTRON GUN, ACCELERATED TO HIGH VELOCITY, SHAPED INTO A BEAM BY ELECTRICAL FIELDS, AND THEN FURTHER COLLIMATED, OR MADE PARALLEL, AND FOCUSED BY AN ELECTROMAGNETIC LENS. SCENE 60. tape 523, 10:23:58-10:24:15 zoom in, electron beam welding THIS ELECTRON STREAM IS DEVELOPED IN HIGH VACUUM, BUT ACTUAL WELDING CAN BE PERFORMED IN EITHER HIGH VACUUM, PARTIAL VACUUM OR STANDARD ATMOSPHERIC

15 Copyright 1999 Society of Manufacturing Engineers PRESSURE. SCENE 61. tape 520, 07:02:40-07:02:50 GRAPHIC: thick part welded with electron beam, add arrow tape 523, 10:05:52-10:06:00 electron beam welding, part with inaccessible joint BECAUSE OF THE INTENSE AND CONCENTRATED HEAT GENERATED, TOTAL HEAT INPUT IS LOW, MINIMIZING HEAT-AFFECTED ZONE SIZE AND PART DISTORTION. THIS ALSO ALLOWS FOR THE CREATION OF EXTREMELY DEEP AND NARROW WELDS. ADDITIONALLY, JOINTS INACCESSIBLE BY OTHER WELDING PROCESSES CAN BE WELDED. SCENE 62. tape 523, 10:07:44-10:08:00 electron beam welding VIRTUALLY ALL FERROUS AND NONFERROUS METALS, THIN OR THICK, CAN BE JOINED. WELDING SPEEDS ARE FAST, AND FILLER METAL IS NOT GENERALLY REQUIRED. SCENE 63. tape 523, 10:17:33-10:17:45 wide, electron beam welding tape 523, 10:10:45-10:10:55 c.u. joint being welded EQUIPMENT COST FOR ELECTRON BEAM WELDING IS TYPICALLY HIGH AND WELDING IS GENERALLY LIMITED TO MACHINED PARTS ASSEMBLED IN PRIMARILY BUTT, CORNER AND LAP JOINTS. --- FADE TO BLACK ---

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